Kawasaki Ninja Service Manual: Engine Sprocket Installation

Kawasaki Ninja Service Manual / Final Drive / Sprocket, Coupling / Engine Sprocket Installation

Replace the sprocket washer and axle cotter pin.
Install the engine sprocket onto the output shaft.
Apply molybdenum disulfide oil solution to the threads and seating surface of the engine sprocket nut.
Tighten: Torque - Engine Sprocket Nut: 145 N·m (14.8 kgf·m, 107 ft·lb)

NOTE

Tighten the engine sprocket nut while applying the rear brake.

Engine Sprocket Installation

After torquing the engine sprocket nut, bend [A] two sides of the washer over the nut.
Adjust the drive chain slack after installing the engine sprocket (see Drive Chain Slack Adjustment in the Periodic Maintenance chapter).
Install: Pin [A] Chain Guide [B] Engine Sprocket Cover [C]
Tighten: Torque - Engine Sprocket Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

Engine Sprocket Installation

Engine Sprocket Removal

Remove: Engine Sprocket Cover Bolts [A] Engine Sprocket Cover [B] Flatten out the bended washer [A]. Remove the engine sprocket nut [B] and washer. NOTE When loosening the engin ...

Rear Sprocket Removal

Remove the rear wheel (see Rear Wheel Removal in the Wheels/Tires chapter). NOTICE Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place bl ...

Other materials:

ECU Removal
NOTICE Never drop the ECU especially on a hard surface. Such a shock to the ECU can damage it. Remove the upper air cleaner housing (see Air Cleaner Element Replacement in the Periodic Maintenance chapter). Lift up the ECU [A] with rubber protector [B] to disconnect the connectors [C]. ...

DFI System
1. ECU 2. Battery 3. Vehicle-down Sensor 4. Exhaust Butterfly Valve Actuator 5. Vacuum Chamber (Other than US, CA and CAL Models) 6. Air Intake Valve Actuator (Other than US, CA and CAL Models) 7. Air Intake Valve (Other than US, CA and CAL Models) 8. Air Flow 9. Air Intake Solenoid Valve ...

Thermostat Installation
Replace the O-rings [A] with new ones, and apply grease to them. Assemble: O-rings Thermostat Housing [B] Thermostat [C] Thermostat Cap [D] Install the thermostat [A] in the housing so that the air bleeder hole [B] is on top. Tighten: Torque - Thermostat Cap Bolts: 5.9 N ...